Diffuser assembly with buoyancy vessel

ABSTRACT

A diffuser assembly with a buoyancy vessel and a chamber for buoyantly raising the diffuser assembly for maintenance work. The diffuser assembly has a support structure, diffusers connected to the frame, and a buoyancy vessel positioned on the frame, capable of alternating between a state of buoyancy or ballast.

CROSS-REFERENCE TO RELATED APPLICATIONS

None.

FIELD OF THE INVENTION

This invention relates generally to the treatment of liquid, such aswastewater, by diffusion of air or another gas, and more specifically tothe diffusion of air into wastewater for aeration and mixing. Theinvention deals in particular with an improved diffuser assembly ormulti-diffuser module that may be raised individually and separatelyfrom other modules. This invention also relates to a method for raisingand lowering an individual aerator module for inspection, maintenance orrepair, without disturbing the remainder of the modules in a gridstructure in a large wastewater treatment basin.

BACKGROUND OF THE INVENTION

In the treatment of wastewater, it is known in the industry to useaeration equipment in order to aerate and mix the wastewater. Thisaeration equipment may be positioned generally at the bottom of thewastewater basin at an intermediate level in the basin, or allowed tofloat on the surface of the wastewater reservoir. It is common to usesubmerged diffusers capable of discharging air into the treatment basin.An example of a particularly effective diffuser is a flexible membranediffuser. U.S. Pat. No. 5,846,412 issued to Tharp provides an example ofan air diffuser and mounting arrangement for use in a water treatmentsystem.

One arrangement for aerating and mixing large wastewater basins makesuse of a large number of diffusers contained in separate multi-diffusermodules in a grid pattern throughout the basin. The aeration equipmenttypically includes a large capacity gas supply source for supplying airto the diffusers. Each individual diffuser is connected to the main airsupply conduit via a branch conduit with the diffusers appropriatelylocated throughout the basin to provide thorough mixing and aeration.

When many individual diffusers are positioned in a grid pattern toaerate a large wastewater treatment reservoir, general maintenance andrepair become problematic. Locating and retrieving an individualdiffuser module is difficult for a variety of reasons. Mechanicalretrieval can be expensive and cumbersome, requiring massive cranes topull each module up from the bottom of the basin. Modules may be locatedin the center portion or a far-side portion of the basin where theycannot be accessed at all by a crane. In large basins, many modules areinaccessible even to cranes with lengthy booms.

After the repair or maintenance is completed, the individual modulesmust be placed back in position on the bottom surface of the basin,again with a crane. In order to position the module in the properorientation on the bottom surface of the basin, the module should notappreciably tip or roll during its descent, which might result in thestructure landing improperly on its side or planing sideways duringdescent. Likewise, if a module is removed from a diffuser gridstructure, it should be carefully repositioned within the pattern of thegrid. The module should be lowered steadily over its position within thegrid, preferably with the module being maintained substantiallyhorizontal as it descends.

In some applications, the main air supply pipes or laterals float on thesurface with large diffuser modules suspended from them above the bottomof the basin. The modules are typically suspended on a plurality offlexible air supply lines attached to the floating air laterals.Retrieval of these large diffuser modules in this type of systempresents the same types of problems as with bottom mounted modules.

SUMMARY OF THE INVENTION

The present invention is directed to a diffuser assembly with a buoyancyvessel arrangement that is capable of providing individual raising,surface retrieval and lowering of the diffuser assembly separately fromother diffuser assemblies in a grid for maintenance or repair of theindividual diffusers.

In accordance with one embodiment of the invention, a diffuser assemblyor module for use in a wastewater basin is provided where the diffuserassembly includes a frame; a plurality of diffusers positioned on theframe, and a buoyancy vessel (or vessels) positioned over or as part ofthe frame and including an air inlet conduit and a flow control. Thediffuser assembly can be part of a diffuser grid structure where airsupply conduits are positioned generally in a grid pattern throughoutthe bottom of the wastewater treatment basin. Each diffuser assembly maybe connected to the main supply conduit by an air supply conduit whichis preferably flexible but which may be rigid or semi-rigid. Theflotation chamber of the buoyancy vessel is preferably positioned at thelevel of the diffusers or partially above the diffuser assembly and isoperable to provide buoyancy to raise and lower each diffuser assemblyin the desired substantially horizontal orientation when diffusermaintenance is necessary, or alternatively, it may provide ballast (whenfilled with liquid) to lower the unit back to its operating position inthe wastewater treatment basin. In order to raise a diffuser assembly,an air control valve can be operated to apply air through an air line tothe flotation chamber. The entering gas will displace liquid out of thebuoyancy vessel through a buoyancy vessel opening. The buoyancy vesselopening, in one embodiment, is at the end of a down turned elbow, withthe opening being positioned below the lowest portion of the buoyancyvessel when the vessel is in a substantially horizontal orientation.This configuration selectively prevents air from escaping the chamber,effectively providing a non-mechanical seal without requiring anymechanical valves or elements to close the opening.

Once the flotation chamber has enough air to make the diffuser assemblybuoyant, the diffuser assembly will rise to the surface of thewastewater treatment reservoir with the pressure of the air decreasingduring the rise, allowing it to expand and increase the air volume andhence buoyancy. Once the diffuser assembly has reached the surface, itmay be moved to the edge of the basin and removed from the basin eitherby hand or using some type of lift such as a crane. Alternatively, thediffusers can be inspected, repaired or replaced while the unit is inthe basin on the surface. Depending on the location of the diffuserassembly relative to the edge of the wastewater treatment basin, it maybe desirable to disconnect the air supply from the main air supplyconduit. After any maintenance or repairs are conducted, and theoperator wishes to return the diffuser assembly to its position in thediffuser grid structure, the diffuser assembly is returned to itsprevious position on the surface of the wastewater treatment basin. Ifthe air supply has previously been disconnected, it may be reconnectedat this time. The operator, in one embodiment, may introduce liquid intothe flotation chamber by utilizing the air control valve to bleed airout of the flotation chamber. This causes liquid to re-enter theflotation chamber and act as ballast to sink the unit.

The orientations of the non buoyant components of the diffuser assemblyrelative to the buoyant components help ensure the diffuser assembly'sreturn to the bottom of the wastewater treatment basin floor in asubstantially horizontal orientation. In a preferred embodiment, twosymmetrical flotation chamber portions extend along the lateral edges ofthe frame and substantially above the center of gravity of the diffuserassembly. This arrangement of the chamber is particularly effective inreducing the tendency of the diffuser assembly to roll or tip duringdescent to the basin floor. Also, at least a portion of the flotationchamber may be positioned above the center of mass or center of gravityof the diffuser assembly when buoyant so that the non-buoyant portion isconfigured to act as a stabilizer or counterpoise, which inhibitsrolling or tipping of the unit, particularly during descent into thebasin.

DESCRIPTION OF THE DRAWINGS

In the accompanying drawings, which form a part of the specification andare to be read in conjunction therewith in which like reference numeralsare used to indicate like or similar parts in the various views:

FIG. 1 is a top plan view of a diffuser module or assembly constructedaccording to one embodiment of the present invention, with portionsbroken away for illustrative purposes;

FIG. 2 is a side elevational view of the diffuser assembly shown in FIG.1;

FIG. 3 is a side elevational view of the buoyancy vessel shown in FIGS.1 and 2;

FIG. 4 is a top plan view of a plurality of diffuser assemblies arrangedin a grid pattern in accordance with one aspect of the invention;

FIG. 5 is a top plan view of a diffuser module or assembly constructedaccording to another embodiment of the invention, with portions brokenaway; and

FIG. 6 is a side elevational view of the diffuser module or assemblyshown in FIG. 5.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings in more detail and initially to FIG. 1,the present invention relates in a preferred embodiment to a diffuserassembly or module 10 for use individually or in a diffuser gridstructure containing a number of the modules 10. The module 10 has anon-buoyant portion 11 and a selective buoyant portion 14. Thenon-buoyant portion includes a frame 20 and a diffuser assembly 22comprising a plurality of individual diffusers 24 arranged parallel toone another. The selective buoyant portion 14 includes a buoyancy vessel12 having an interior flotation chamber 19. The frame 20 supports thediffuser assembly 22 and the buoyancy vessel 12, operably connecting thestructures together. In the illustrated embodiment in FIGS. 1 and 2, theframe 20 has a generally rectangular shape, although the frame couldhave any suitable shape and size. As used herein, non-buoyant means theobject has a density greater than the liquid it is in and will not floaton its own and buoyant means the object will float on its own and has adensity (including a chamber and its contents) less than the liquid itis in.

As shown in FIGS. 1 and 2, the diffuser assembly 22 includes a centralheader pipe 28 providing a supply of air to the diffusers 24. Air issupplied to header pipe 28 by an air supply conduit 40 which may beequipped with a quick disconnect coupling 44. The diffusers may betubular membrane diffusers of the type having rigid tubes 23 thatreceive flexible membranes 25. The size and position of the diffusers 24may be varied to suit the needs of the particular wastewater treatmentprocess. For simplicity, only representative membranes 25 are shown inFIG. 1. Other types of diffusers can be employed, including diskdiffusers and coarse bubble diffusers.

The frame of the diffuser assembly includes a series of transverseballast beams 18 (FIG. 2) positioned below the diffusers 24. The ballastbeams 18 are positioned and sized to provide the ballast required tokeep the diffuser module 10 positioned on the bottom of a wastewaterbasin when operating. The header pipe 28 may be strapped, bolted orotherwise secured on top of the ballast beams 18 at a location extendingalong the longitudinal axis of the module 10. The wastewater basin mayhave an earthen, polymeric, metallic or concrete bottom which may invokedifferent details in the construction of the module 10, particularly inthe portions adjacent the bottom.

The buoyancy vessel 12 may take the form of a U-shaped tubular structurethat has side portions 12A, 12B preferably extending generally along thelength of the assembly parallel to the pipe 28 and perpendicular to thediffusers 24. Coaxial end portions 12C and 12D connect with therespective side legs 12A and 12B through elbow fittings. The shape andsize of the buoyancy vessel 12 and chamber 19 may be selected to fit thesize profile and buoyancy needs of the module 10. The components thatare buoyant during lift are sized and positioned to effect the lift anddescent of the module 10 in the wastewater reservoir. Lift and descentmay be controlled as discussed below. Additionally, the flotationchamber 19 is preferably positioned relative to the remainder of themodule 10 so at least some portion of the chamber 12, and preferably allof it, is located at or above the center of mass (designated CM in FIG.2) of the non-buoyant portion 11 when the module 10 is in a horizontalorientation. It is not necessary but preferred for the entire body offlotation chamber 19 to be above the non-buoyant portion 11. Thisconfiguration enhances stability and allows the module 10 to descend ina substantially horizontal orientation, which limits planning, rollingor flipping of the module 10 during descent.

The configuration, size and orientation of the chamber 19 determines thelocation of the center of lift (designated as CL in FIG. 2), and thecenter of lift may change as gas flows in or out of the chamber. Thecenter of lift is the general mean point where the lift forces exertedby the air in the chamber 19 may be considered to be focused. The centerof lift relative to the center of mass may vary as the chamber 19 variesbetween ballast and buoyancy, i.e., as the relative amounts of gas andliquid in the chamber 19 changes.

The buoyancy chamber 19 is in flow communication with gas supply linessuch as a pair of flexible air hoses 30 each having a three-way airvalve 32. One of the hoses 30 connects to chamber portion 12C and theother hose 30 connects with portion 12D. The portions 12C and 12D arepreferably isolated so that flow between them is not permitted Thebuoyancy vessel 12 terminates in one or more flow control sections 33,each of which may take the form of a down turned elbow 16 presenting aflow control opening 36 communicating between chamber 19 and theexterior to the chamber 19. The opening 36 may be at the lower end of aspout 34. The opening 36, in the illustrated structure can function asan inlet and an outlet for liquid, as will be described. In oneembodiment, the elbow 16 forms a generally 90° angle following a bend35.

The opening 36 is shown as positioned below the level of the center oflift CL when the module 10 is relatively horizontal or level, to allowthe opening 36 to function as a self-sealing hydraulic seal when air isin the chamber 19, thereby forming a valve with no mechanical valveelements. It is preferred that the end portion of each side leg 12A and12B of the flotation chamber be equipped with a flow control section 33and a flow control opening 36.

The module 10 is normally located in a wastewater treatment basinsubmerged either on the basin bottom or suspended from floating airlaterals. In either case, when air is supplied through hose 40 to theheader pipe 28, the air is directed into the diffusers 24 and dischargedthrough slits in the membranes 25 into the wastewater in the form offine bubbles. This effects aeration and mixing of the wastewater withthe fine bubbles efficiently transferring air to the liquid.

If the operator wishes to raise the module 10, he or she may commencepurging liquid from the chamber 19 through the openings 36 by firstopening the air valves 32 to allow gas under pressure to enter thechamber 19 through hoses 30. The following described process will applyto all the embodiments described in this application, but for simplicitythis description will only refer to the embodiment shown in FIGS. 1-3.In any embodiment, the chamber 19 is generally filled with liquid whenthe module 10 is in an operating position on the bottom of thewastewater treatment basin.

As the gas enters the chamber 19, it displaces liquid in the chamber andpurges it through openings 36 in flow control sections 33. As the gasdisplaces the liquid in the chamber 19, the module 10 becomes buoyantand begins to lift off the bottom surface of the wastewater basin, firstnear the end of the module where the gas is introduced into the chamber19, which is opposite openings 36. While a plurality of openings 36 andflow control sections 33 are shown, the use of only one of each cansuffice in some applications.

As the air enters the chamber 19, openings 36 act as hydraulic seals toprevent gas from escaping the chamber, so long as the openings 36 remainbelow the level of the chamber 19. In a preferred embodiment, the elbow16 and position of the openings 36 relative to the chamber 19 createthis self-sealing feature without the use of mechanical valve elementsor moving parts or other mechanical closures or devices.

The absence of mechanical valves provides for a more trouble freeproduct for use in environments such as wastewater treatment. Mechanicalmethods to seal the opening could easily become blocked or corroded inthe sludge or materials processed by most wastewater treatment works.The absence of mechanical valve obstacles within the flow controlsection 33 means the present invention offers fewer opportunities forrepair problems or malfunction delays. In a less preferred embodiment,the flow control sections 33 could include a mechanical valve upstreamfrom the respective opening 36 for selectively opening and closing thechamber 19 to liquid flow.

Once the gas has displaced most of the liquid from the buoyancy vessel12, the module 10 will rise as a result of its buoyancy and approach thesurface of the liquid in the basin. The operator may then retrieve themodule by any convenient method, including towing from a boat or removalby crane. The module 10 may be removed for servicing, repair, orreplacement of the diffusers 24 or other components. It may also beserviced while at the surface without removal from the basin. The module10 can be moved to an edge of the basin where it can be lifted or, oftenmore conveniently, tilted and then lifted out of the basin.

When the operator desires to install the module 10 in the basinfollowing maintenance, he or she can position the module 10 on thesurface of the wastewater at the desired location. The operator willthen begin to bleed gas from the buoyancy chamber 19 by positioning thethree-way valves 32 to allow air to escape from the flotation chamber19. As the air escapes the chamber 19 through the conduits 30, liquidwill begin to re-enter the buoyancy vessel through the openings 36. Asthe liquid re-enters the buoyancy chamber 19, the vessel 12 begins tolose buoyancy, causing the module 10 to begin its descent to the bottomof the wastewater basin.

The center of lift CL of the buoyant portion 14 is generally above thecenter of mass CM of the non-buoyant portion 11. The force vector at thecenter of lift CL is generally in line with and generally above theforce vector due to the counterpoise weight of the non-buoyant portion14. Also, at least a portion of the chamber 19 is preferably positionedabove the center of mass of the non-buoyant portion 11. For stability,the buoyant portion includes two chamber legs 19A, 19B located in sides12A, 12B and each extending along a respective side portion of themodule 10. Additionally, the chamber legs or portions 19A, 19B areconnected to the separate infeed hoses 30 by vessel portions 12C, 12Dwhich also have a respective chamber portion 19C, 19D therein eachcommunicating with the chamber portions 19A, 19B. The chamber portions19C, 19D are isolated from each other and provide for buoyancy at theend of the module 10 opposite that of the location of the flow controlsections 33. Accordingly, the end of the unit opposite the openings 36normally rises first and descends last, providing a slight cant orinclination to the module 10. This can help achieve and maintain a sealin the flow control sections 33 while still substantially preventingplanning of the diffuser module, particularly during descent.

In an alternative embodiment, a single vessel 12 with a single chamber19 therein may be provided and preferably would be positioned generallyalong the longitudinal central axis of the module 10. By proper relativepositioning of the center of mass and the center of lift, appropriateascent and descent may be accomplished. However, two separate chambersspaced apart on opposite sides of the unit is preferred because such aconfiguration enhances the stability much in the manner of a doublepontoon boat.

FIG. 4 illustrates a plurality of modules 10 positioned in a basin 60 ina grid configuration. A gas supply conduit 61 extends along a portion ofthe reservoir and preferably along a substantial length of a grid system60. The gas supply conduit is provided with a plurality of gas supplybranch conduits 62 connected thereto, each also being connected in flowcommunication with a respective module 10 through one of the valves 32.The supply conduit 62 connects through valve 32 with both the gas lines30 and the header pipe 28 so that air can be fed to either the diffusers24 or the buoyancy vessel 12. When it is desired to raise a module 10,air is fed primarily to the chamber 19 with zero to low air flow to thediffusers through appropriate operation of the valving. A respectivemodule 10 of the grid may be raised or lowered for appropriatemaintenance or inspection in the manner previously described.

FIGS. 5 and 6 depict an alternative embodiment of the invention whichincludes a modified diffuser module 110. The module 110 is equipped witha diffuser assembly which may be of any desired type, including aplurality of large tube diffusers 123 which may be clustered relativelyclosely together, individual tube diffusers 124 which may be spacedcloser together and may be smaller overall than the diffusers 123, or aplurality of disk diffusers 126 mounted along the length of supply pipes126 a. Diffusers 123 may be equipped with flexible membranes 123 a whichdischarge air into the wastewater in the form of fine bubbles.Similarly, diffusers 124 may be equipped with flexible membranes 124 athrough which air is transferred to the wastewater in the form of finebubbles. The disk diffusers 126 may be of any suitable type, includingbodies having their faces equipped with flexible disk membranes throughwhich air in the supply pipes 126 a is delivered to the wastewater inthe form of fine bubbles.

The diffusers 123, 124 and/or 126 are mounted on and receive air from ahorizontal header pipe 128 which in turn receives air from a blower (notshown) through an air supply conduit 140 which may be a flexible hose.The header pipe 128 extends along the longitudinal center line of themodule 110. Ballast beams 118 are secured to the header pipe 128 nearits opposite ends by suitable straps 131 or other fastening means.

The module 110 is equipped with a single buoyancy vessel 112 which maybe located above the header pipe 128 and arranged to extend above pipe128 along the longitudinal center line of the diffuser module 110. Thebuoyancy vessel 112 may take the form of a pipe having a hollow interiorforming a flotation chamber 119 (FIG. 6). One end of vessel 112 may beequipped with a down turned elbow 116 which in turn connects with ashort vertical spout 134. The lower end of the spout 134 is open toprovide a flow control opening 136 that functions in substantially thesame manner as opening 36. The buoyancy vessel 112 may be connected withthe module 110 in any suitable manner such as being formed as part of aframe that includes the diffuser module and buoyancy vessel 112.

Air is supplied to and bled from the buoyancy vessel 112 through an airhose 130 that connects with the vessel 112 at the end opposite the spout134. The air hose 130 may be equipped with a valve such as a three-wayair valve 132. The end of the buoyancy vessel 112 adjacent to theconnection of the air hose 130 may be provided with a down turned leg155 that connects with the header pipe 128.

The diffuser module 110 may be lifted to the surface by a pair ofretrieval cables 157, each connected with a harness 159. The twoharnesses 159 connect with the two ballast beams 118 near the oppositeends of the beams.

The embodiment of FIGS. 5 and 6 functions and operates in substantiallythe same manner as described for the embodiment of FIGS. 1-4. Thebuoyancy vessel 112 may be supplied with air through the hose 130 inorder to effect a buoyant condition of the module 110, causing it torise to the surface for maintenance and/or repair. The flow controlopening 136 functions as a valve to confine the air in the buoyancyvessel 112 while avoiding the ingress of water due to the air pressure.When the buoyancy vessel 112 is bled of air through the air hose 130,water enters the flotation chamber 119, and the module 110 then revertsto a non-buoyant condition in which it descends to the basin floor 113and remains in place on the floor until it is again made buoyant.

Thus, there has been shown and described several embodiments of a novelinvention. As is evident from the foregoing description, certain aspectsof the present invention are not limited by the particular details ofthe examples illustrated herein, and it is therefore contemplated thatother modifications and applications, or equivalents thereof, will occurto those skilled in the art. The terms “having” and “including” andsimilar terms as used in the foregoing specification are used in thesense of “optional” or “may include” and not as “required”. Manychanges, modifications, variations and other uses and applications ofthe present construction will, however, become apparent to those skilledin the art after considering the specification and the accompanyingdrawings. All such changes, modifications, variations and other uses andapplications which do not depart from the spirit and scope of theinvention are deemed to be covered by the invention which is limitedonly by the claims which follow.

1. A diffuser module for use in aerating wastewater, said diffuser module comprising: a support structure; a diffuser assembly mounted to the support structure and having, a plurality of diffusers for applying air to the wastewater; at least one buoyancy vessel mounted to the support structure and having a flotation chamber, said vessel being positioned such that a portion of the chamber is positioned above a center of mass of the support structure and diffuser assembly; and a flow control opening in flow communication with the chamber and operable to selectively seal the chamber from gas discharge and selectively permit discharge of liquid from the chamber when gas is applied thereto.
 2. The module of claim 1, wherein said chamber includes spaced apart sides extending generally along opposite sides of said diffuser assembly.
 3. The module of claim 2, including a depending leg extending generally downwardly from said chamber and presenting said flow control opening at a location below the chamber.
 4. The module of claim 3, wherein said leg forms part of an elbow member on said vessel.
 5. The module of claim 2, wherein said chamber sides are on opposite sides of a center of mass of the module.
 6. A diffuser module as set forth in claim 1, wherein said buoyancy vessel comprises a pair of fluid chambers separate from one another.
 7. A diffuser module as set forth in claim 1, wherein said at least one buoyancy vessel comprises a single vessel. 